Classifications

• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G63/00—Macromolecular compounds obtained by reactions forming a carboxylic ester link in the main chain of the macromolecule
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G63/00—Macromolecular compounds obtained by reactions forming a carboxylic ester link in the main chain of the macromolecule
  • C08G63/68—Polyesters containing atoms other than carbon, hydrogen and oxygen
  • C08G63/692—Polyesters containing atoms other than carbon, hydrogen and oxygen containing phosphorus
  • C08G63/6924—Polyesters containing atoms other than carbon, hydrogen and oxygen containing phosphorus derived from polycarboxylic acids and polyhydroxy compounds
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G63/00—Macromolecular compounds obtained by reactions forming a carboxylic ester link in the main chain of the macromolecule
  • C08G63/68—Polyesters containing atoms other than carbon, hydrogen and oxygen
  • C08G63/692—Polyesters containing atoms other than carbon, hydrogen and oxygen containing phosphorus
  • C08G63/6924—Polyesters containing atoms other than carbon, hydrogen and oxygen containing phosphorus derived from polycarboxylic acids and polyhydroxy compounds
  • C08G63/6928—Polycarboxylic acids and polyhydroxy compounds in which at least one of the two components contains aliphatic unsaturation
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G63/00—Macromolecular compounds obtained by reactions forming a carboxylic ester link in the main chain of the macromolecule
  • C08G63/91—Polymers modified by chemical after-treatment
  • C08G63/914—Polymers modified by chemical after-treatment derived from polycarboxylic acids and polyhydroxy compounds
  • C08G63/918—Polycarboxylic acids and polyhydroxy compounds in which at least one of the two components contains aliphatic unsaturation
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L67/00—Compositions of polyesters obtained by reactions forming a carboxylic ester link in the main chain; Compositions of derivatives of such polymers
• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
  • C09D167/00—Coating compositions based on polyesters obtained by reactions forming a carboxylic ester link in the main chain; Coating compositions based on derivatives of such polymers
  • C09D167/06—Unsaturated polyesters having carbon-to-carbon unsaturation
  • C09D167/07—Unsaturated polyesters having carbon-to-carbon unsaturation having terminal carbon-to-carbon unsaturated bonds

Definitions

• the present invention is directed towards water-thinnable phosphorous-containing polymer precursors, their preparation and use.
• the precursors of the invention are useful in compositions for preparing coatings which impart and/or exhibit resistance to attack, for example which are useful as flame-retardant coatings.
• phosphorous containing materials as flame retardants is well known. It is believed that in the presence of a flame source they act by, for example, forming phosphoric and polyphosphoric acids of low volatility which catalyse the decomposition of organic compounds to carbon (char) and water. Non volatile phosphorous containing compounds may also coat the char to protect it from further oxidation, and this may act as a physical barrier and/or reduce the permeability of the char. It is believed that in general the greater the phosphorous content of the material the better its flame resistance.
• halogen-containing monomer to prepare a flame-retardant composition
• fire halogen groups can generate toxic and corrosive combustion products. These corrosive gases, in addition to their toxic properties cause significant damage to electronic components, present in particular in computers, which very often results in the loss of essential data and irreparable damage, often worse than the fire itself.
• the combustion products from halogen-containing materials may even be as dangerous as combustion products from materials untreated with flame-retardants. It is also undesirable to use halogen compounds for other reasons such as their potentially undesirable effect on the environment Therefore, preferably the polymers and polymer precursors of the invention are substantially free of halogen.
• co-polymerisable compounds containing phosphorous have been developed in which the phosphorous atom is linked to the backbone of a polymer precursor through a chemical reaction in which a covalent bond is formed.
• This method of incorporating phosphorous is advantageous because as the phosphorous moieties are permanently linked to the backbone of the resultant polymer, there is no blooming effect and there are no compatibility issues as can be the case when incorporating phosphorous containing additives.
• Use of phosphorous containing polymer precursors also has a reduced influence upon the physical and mechanical properties of the resultant polymer. For example solid flame retardant additives can undesirably increase the viscosity of a polymer to which they are added.
• Polyester are compounds (usually polymer compounds) containing at least 2 ester functionalities.
• Radiation-curable polymers can be acrylate polymers i.e. polymers containing radiation-curable acrylate functionalities.
• Polyester acrylates (PEA) and polyester urethane acrylates (PEUA) represent an important polymer class of radiation curable polymers as they are often used as polymer precursors to make polymer coatings (such as UV curable resins and UV curable powder coatings) for thermally sensitive substrates such as wood or MDF (medium density fiber). Therefore it is desirable to incorporate phosphorous in polyester acrylates to provide these polymers with intrinsic flame retardant properties, particularly as safety regulations become more stringent.
• Phosphorous-comprising polyols useful in the preparation of flame-retardant coatings are disclosed in WO 00/52016. Polyesters are not disclosed.
• U.S. 2002/0013391 discloses a flame retardant resin coating comprising a flame retardant base resin and a transparent resin top layer.
• the base resin comprises color pigments giving a certain coloring to the coating material and, preferably, about 2,5 tot 50% by weight of a flame retardant additive.
• the base resin may comprise phosphorus-containing polyurethanes.
• Water-soluble resins or resin precursor are not contemplated.
• WO 01/74826 describes a co-polymerisable phosphorous containing polymer precursor which can be polymerised with other monomers to produce co-polymers such as phosphorous containing polyurethanes which for example have use as flame-retardants, anti-corrosives, pigment dispersants and/or adhesion promoters.
• radiation curable resins require low viscosity.
• the composition should have a viscosity in the range of 500–10.000 mPa ⁇ s.
• viscosities in the range of 150–250 mPa ⁇ s are preferred, for spray gun applications the viscosity should be in the range of 30–100 mPa ⁇ s and with a vacuum coater viscosities of 50–200 mPa ⁇ s are preferred.
• Low viscosities are typically achieved by adding acrylated monomers (also called dilution monomers).
• Low viscosity is typically achieved by adding acrylated monomers (also called dilution monomers).
• the applicant has developed a new class of improved phosphorous containing materials which exhibit utility in the applications described herein, for example having improved flame-retardant properties.
• the applicant has also discovered improved processes for preparing such materials which address some or all of the problems of the prior art such as those described herein.
• the phosphorous containing materials of the present invention are water-thinnable so that their viscosity can be easily adjusted by water-addition without use of dilution monomers.
• Water-thinnable means making more fluid by adding water as thinner (diluent).
• the present invention relates to a process for preparing a water-thinnable phosphorous-containing polymer precursor which polymer precursor is a radiation-curable polyester, which process comprises the steps of (a) providing a polyester which comprises phosphinate ester (P—O—C) bonds and (b) hydrolysing at least part of said phosphinate ester (P—O—C) bonds.
• the present invention relates to a water-thinnable phosphorous-containing polymer precursor which is obtainable from the above process as well as a flame-retardant composition comprising the above polymer precursor and a flame-retardant coating obtainable by curing such composition.
• This invention permits to prepare water soluble halogen-free flame retardant UV curable resins with high stability toward hydrolysis and decantation.
• polyesters in the sense of the present invention can be polymers and polymer precursors comprising a plurality of di- or polycarboxylic acid residues and a plurality of di- or polyol residues.
• the polyesters may additionally comprise further co-monomers such as in polyester acrylates or polyester urethane acrylate.
• the polyesters used in the process of the present invention comprise at least one phosphinate ester (P—O—C) bond.
• a phosphinate ester is a compound of the formula RR′P(O)(OR′′).
• phosphinate ester bonds are the bonds between the phosphorous atom and the oxygen atom of the OR′′ moiety and the oxygen atom and the first carbon atom of the OR′′ moiety.
• Said phosphinate ester (P—O—C) bonds can be hydrolysed preferably in basic medium to form a RR′P(O)(O)— moiety and an HOR′′ moiety.
• the so-formed phosphinate salt residue imparts water-solubility and, thus, water-thinnability to the polymer precursor of the present invention: If hydrolysis is performed in water without base, the pH will become progressively acid ( ⁇ 7) due to the acid character of P—OH (phosphinic acid) and hydrolysis of the polyesterbackbone may occur.
• the phosphinate ester (P—O—C) bonds are located in one or more side chains of the polyester to avoid a cleavage of the polyester backbone during the hydrolysation step. If the phosphinate ester (P—O—C) bonds are in the side chain(s) of the polyester the phosphorous atom of said phosphinate ester (P—O—C) bonds forms part of the backbone of said polyester, i.e. the groups R and R′ in the above general formula RR′P(O)(OR′′) form the polyester.
• the phosphorous atom of the phosphinate ester (P—O—C) bonds is directly or indirectly bonded to the backbone of said polyester via a bond which is not said phosphinate ester (P—O—C) bond.
• the phosphinate ester (P—O—C) bonds including their phosphorous atom are located within a side chain of the polyester such that when the hydrolysation step is carried out the phosphorous atom will not be cleaved from the polyester backbone and, in turn, is still present in the final polymer precursor obtained in the process of the present invention to impart the desired flame-retardant properties.
• phosphinate ester P—O—C bonds are hydrolysed selectively without hydrolysing the polyester backbone of the polymer precursor. It is also desirable that the hydrolysis of the phosphinate ester gives a water soluble product, (homegeneous; no decantation) and clear. It is also desirable that the pH of the water-thinnable resin is between pH 6 and 8 in order to avoid further hydrolysis of the polyester backbone with time. Applicant has found that these three desirable properties can be obtained by carrying out the hydrolysis step with a base in the presence of an alcoholic solvent.
• the alcoholic solvent can for example be selected from straight, branched or cyclic, saturated or unsaturated C 1-6 -alkanols. Particularly preferred examples of the alcoholic solvent are methanol, ethanol, n-propanol, isopropanol, n-butanol, isobutanol and tert.-butanol.
• the hydrolysis of the phosphinate ester (P—O—C) bonds in the process of the present invention is facilitated by the presence of a base that is preferably dissolved in water.
• the base is an organic or an inorganic base, preferably an inorganic base and more preferably a strong inorganic base.
• the base exhibits a pK B value below 4 and more preferably below 2.
• the hydrolysis step occurs in a very short time with quantitative yields and without any purification steps.
• Preferred bases are alkali metal hydroxides such as sodium hydroxide and potassium hydroxide. Mixtures of two or more different bases and/or two or more different alcoholic solvents can also be employed.
• a preferred process of the present invention can be depicted in the following reaction scheme. This reaction scheme is not limitative and is given only to illustrate possible reaction and compounds.
• the polymer precursor obtainable from the above described process is useful for preparing a flame-retardant composition having a high phosphorous content because no dilution monomers are necessary to achieve a low viscosity because due to the hydrolysed phosphinate ester (P—O—C) bonds the polymer precursor is water-soluble and, thus, water-thinnable. Therefore the target viscosity can be achieved by the addition of water without detrimental effects on the flame-retardancy performance because the water is evaporated when applying the flame-retardant composition to a substrate surface.
• P—O—C hydrolysed phosphinate ester
• the viscosity of the polymer precursor obtainable by the process of the present invention and, thus, the flame-retardant composition of the present invention can easily by adjusted by the addition of water within a range of e.g. 10.000 mPa ⁇ s up to 50 mPa ⁇ s.
• the polymer precursor obtainable by the process of the present invention is cured by UV or electron beam irradiation to form a flame-retardant coating on the surface of the substrate.
• the polyester polymer precursor preferably comprises at least two acrylic or methacrylic groups so that the precursor can be cured by UV or electron beam irradiation.
• the polymer precursor preparable by the process of the present invention is preferably a polyester urethane acrylate and more preferably, polyesteracrylate.
• a new and advantageous product is obtainable by a process according to the present invention.
• a water thinnable radiation curable resin based on a phosphorus based polyester acrylate can be obtained by a process comprising a selective hydrolysis of a phosphinate ester bond in the presence of an alcoholic solvent so as to obtain a fast hydrolysis and a water thinnable homogeneous and transparent resin. This occurs without hydrolysis of the polyester backbone.
• the flame-retardant composition obtainable from the present polymer precursor may present an excellent adhesion on substrates such as wood.
• a coating comprising a flame-retardant layer over a substrate
• layer (layer ( 1 )) can be and is preferably a base coat (primer) on the substrate.
• This primer that confer flame-retardancy can be overcoated with a further layer (layer ( 2 )).
• Said further layer optionaly contains sublayers.
• Layer ( 2 ) often contains one or several sealers and a topcoat.
• the substrate is visible and that is desired in many applications such as wood floors.
• At least, some of these other layers can be non flame-retardant layers, such as non-phosphorous or non-halogenated coatings without affecting negatively the flame-retardant performance of the all system.
• excellent flame-retardant properties can be combined with excellent abrasion and scratch resistance.
• Overcoatings with a or several sealers and a topcoat useful for the flame-retardant coatings of the present invention are for example described in EP-A-1 167 463 the content of which is incorporated into this application by reference.
• the FR-primer that confer flame-retardancy can be overcoated with one or several FR-sealers (100% solid), one or several sealers (non-phosphorus based) and a topcoat.
• FR-sealers 100% solid
• sealers non-phosphorus based
• topcoat a topcoat
• additives non copolymerizable
• non copolymerizable can also be incorporated in one or several layers.
• a substrate is any material on which one or several layers are applied. It can be wood, MDF, HPL (high pressure laminate), paper, cardboard, plastics, cable, metal, optical fibres or combinations of these materials.
• the MDF-wood substrate states for an MDF layer (+/ ⁇ 8 mm thickness) laminated with a beech veneer (+/ ⁇ 1 mm thickness) typically used for parquet flooring application.
• a system is defined as the MDF-wood substrate coated with one or several layers.
• a layer is a primer or a sealer or a topcoat.
• a layer is applied in one or several times, for example by roller coater.
• a layer can be cured by UV or EB irradiation.
• the primer is the first layer applied on a substrate.
• the substrate is a MDF-wood subtrate.
• it is based on a water-thinnable polymer described in this invention.
• the water is preferably evaporated before UV-EB curing.
• the sealer is the second layer applied on the primer.
• the first sealer is applied on the primer
• the second sealer is applied on the first sealer.
• the topcoat is the layer applied on the sealer. If two sealers are used, the topcoat is applied on the second sealer.
• FR states for flame retardant, especially for phosphorus containing flame retardant, compositions.
• FR-primer means that the primer contains phosphorus
• the sealer contains at least one layer whose composition is different from the primer water-thinnable layer.
• This at least one layer can be a FR layer or a non FR layer.
• a water-thinnable FR primer according to the invention is overcoated with a (sealer) FR non water-thinnable layer according to the patent application PCT/EP02/02390 whose content is incorporated herein by reference.
• the sealer layer is then preferably overcoated by a topcoat imparting desired appearance to the coated substrate.
• the sealer and topcoat can provide the required abrasion resistance especially for flooring applications.
• the whole coating may present together as well flame-retardancy as abrasion resistance properties, even if all layers over the FR water-thinnable primer do not have FR properties.
• the coating contains 2 FR layers, the water-thinnable layer can be of lower thickness: the manufacturing process is thus facilitated (less water to be evaporated).
• the sealer and the topcoat which imparts abrasion-resistance to the coating is transparent.
• the FR-primer is also preferably transparent.
• the present invention relates to the use of the flame-retardant composition as described above for coating a substrate as well as a substrate at least part of which is coated with the flame-retardant coating of the present invention.
• substrate for example wood, MDF, HPL, plastics, paper, cardboard, cable, optical fibres and metal is suitable.
• the coating has not only flame-retardant properties but is also useful as anticorrosive coating, adhesion promotor (e.g. for metal substrates) and due to its good pigment wetting properties is applicable for inks.
• the phosphorous-containing polymer precursor of the present invention can be prepared in a “First Process”, wherein certain phosphorous-containing acrylatable (e.g. hydroxy- and/or carboxy-terminated) reactive oligomers (“First Polymer”) are obtained.
• First Polymer phosphorous-containing acrylatable (e.g. hydroxy- and/or carboxy-terminated) reactive oligomers
• These First Polymers can be used in a “Second Process” to prepare (as a “Second Polymer”) phosphorous-containing polyesters such as polyester acrylates and/or polyester urethane acrylates. This is because the plurality of acrylatable functional groups in the First Polymer (for example two or more hydroxy groups in the First Polymer are OH-terminated) can be acrylated without hydrolysis or transesterification side reactions at the oxyphosphorous bond.
• acrylatable functional groups in the First Polymer for example two or more hydroxy groups in the First Polymer are OH-terminated
• the Second Polymers can be used, after hydrolisation of at least part of the phosphinate ester (P—O—C) bonds, in a further (Third) Process to form Third Polymers (such as polymerized cross-linked polymer networks) useful for example as coatings.
• Third Process is performed in situ on for example an article coated with one or more Second Polymers.
• the First Polymer is reacted with at least one acrylating agent to form a radiation-curable polymer precursor (“Second Polymer”).
• acrylating agent is used herein to refer to a compound comprising a) one or more optionally alkylated acrylate group(s), for example (meth)acrylic acid, (meth)acrylate; one or more alkyl(alkyl)acrylate ester(s), for example alkyl(meth)acrylate ester, preferably (meth) acrylic acid which can react with the first polymer by direct esterification or methyl(meth)acrylate ester and/or ethyl(meth)acrylate ester which can react with said reagent (or First polymer) by a transesterification reaction.
• the most preferred process is using acrylic acid (direct esterification).
• the First Polymer can also be reacted with one or more oxiranating and/or isocyanating agent.
• oxiranating agent is used herein to refer to a compound comprising one or more oxiranyl group(s), for example oxirane(s) such as epoxides and/or oxetanes.
• isocyanating agent is used herein to refer to a compound comprising one or more isocyanate groups, e.g. —N ⁇ C ⁇ O.
• the First Polymers may be represented schematically by the following general structure (which is by way of illustration only as should not be considered as limiting to scope of the invention):
• T represents the (at least two) reactive groups such as hydroxy and/or carboxy
• P denotes phosphorus groups which at any position on the polymer such as may be pendant from and/or incorporated into the main polymer chain (polymer backbone).
• the First Polymer is preferably a phosphorus-containing reactive polyester oligomer which may be dihydroxy or dicarboxy terminated.
• the First Polymer can be reacted with many reagents (Second Reagents) in a Second Process to form a Second Polymer.
• the Second Reagents may comprise monoisocyanates, for example isocyanatealkyl(alkyl)acrylates, such as:
• Second Reagents may comprise (alkyl)acryloyl groups for example:
• LG denotes a leaving group under the conditions of the Second Process such as halogen group (e.g. OH, Cl).
• the Second Reagent is acrylic acid.
• the Second Reagent(s) may comprise a plurality of (preferably two) isocyanate groups (i.e. comprise polyisocyanates).
• the Second Reagent(s) may comprise glycidyl(meth)acrylate groups.
• the First Polymer can be preferably (meth)acrylated (direct esterification) with (meth)acrylic acid or transesterified with (alkyl)(meth)acrylate esters to form a preferred Second Polymer which may be represented schematically by for example the following structure (which is by way of illustration only as should not be considered limiting to the scope of the invention):
• each R′ is typically H or alkyl such as methyl.
• the Second Polymers comprise a new class of phosphorus containing polyester and/or urethane acrylates which can themselves be polymer precursor(s).
• the Second Polymer can be further reacted with many reagents (Third Reagents) in a Third Process to form a Third Polymer.
• the Second Polymer can also be used as the starting material in a Third Process of polymerisation (e.g. initiated by radiation) to form, as a Third Polymer, a phosphorus-containing polyester derived polymer.
• the Third Polymer may comprise the polymerisation product of a UV curable polyester acrylate or urethane acrylate after UV irradiation.
• the Third Process may optionally be carried out in situ (for example by UV irradiation of an article coated with a powder composition comprising the Second Polymer) to form as the Third Polymer for example a coating of a cross-linked polymeric network. Because such coatings contain phosphorous they may impart flame retardant properties to the coated article.
• steps (a) and (b) are carried out in a single vessel, more preferably are simultaneous.
• Compounds (I) to (iv) are not necessarily all distinct compounds.
• step (b) the polymerisation is polycondensation.
• a catalyst component (v) may be present during step (a). If present, it is other than one selected from PtCl 4 , NiCl 4 , PdCl 4 , platinium divinyl tetramethyldisiloxane, platinium cyclovinyl methyl siloxane and mixtures thereof.
• a catalyst is present during step (a) which catalyst (component (v)) comprises a tin complex catalyst.
• step (a) of the First Process component (i) comprises a double bond-containing unsaturated dicarboxylic acid, acid anhydride; ester; other condensable derivatives thereof; and/or suitable mixtures thereof.
• component (i) comprises those compounds of Formula I
• Component (i) may usefully comprise at least one unsaturated diacid and/or anhydride selected from
• a double bond polymerisation inhibitor for example, a quinone, such as hydroquinone, butyl quinone, dibutyl hydroquinone, methyl hydroquinone, during the First Process (e.g. polycondensation/esterification reaction) of the present invention.
• the amount of the inhibitors added is preferably from about 500 ppm to about 3000 ppm based on the total amounts of ingredients in the reaction mixture.
• the optional component (ii) comprises a unsaturated or saturated dicarboxylic acid or an acid anhydride thereof.
• component (ii) is saturated.
• saturated dicarboxylic acids, esters or anhydrides that may comprise component (ii) herein are one or more of: adipic acid (HOOC—(CH 2 ) 4 —COOH), sebacic acid, azelaic acid, docecane dicarboxylic acid, diesters of these acids, and/or effective mixtures thereof.
• component (iii) comprises an saturated diol.
• diols that may comprise component (iii) comprise one or more of: ethylene glycol, 1,4-butane diol, 1,6-hexanediol, diethylene glycol, neopenthylglycol, isomers, alkoxylated derivatives thereof (usefully oxypropylated and/or oxyethylated derivatives thereof and/or effective mixtures thereof.
• component (iv) (the oxyphosphorous containing compound) comprises a tertiary organo-substituted phosphorus atom (preferably comprising 3 ⁇ P—C bonds thereon) or a secondary organo substituted phosphorus atom (preferably comprising 2 ⁇ P—C bonds and one resistant oxyphosphorous bond (P—O) thereon).
• a resistant oxyphosphorous bond denotes a P—O bond which does not hydrolyse and/or undergo transesterification under the conditions of the reaction (e.g. due to steric hindrance at the phosphorous and/or oxygen atom(s)) or where such hydrolysis and/or transesterification is readily reversible under the conditions of the reaction (e.g. where both the phosphorous and oxygen atoms of the P—O bond are ring atoms in a larger cyclic group).
• component (iv) comprises compounds of Formulae (I), as described herein and/or effective isomers, salts and/or mixtures thereof.
• At least one phosphinate ester with the following structure should be used:
• Preferred compounds of Formula I comprise compounds of Formula 1
• More preferred compounds of Formula II comprise compounds of Formula 2.
• a preferred compound of Formula I comprises that of Formula 3
• DOPO 9,10-dihydro-9-oxa-10-phosphaphenantrene-10-oxide
• X is a halogen or a group of S, O or Si.
• a main group metal i.e. non transitional metal
• IUPAC Group 14
• tin metal, complex and/or salt for example the tin complex available commercially from Goldschmidt under the trade name Fascat 4102.
• the amount of the catalyst used may be from about 0.001% to about 1% preferably from about 0.01% to about 0.1%, more preferably from about 0.01% to about 0.1% by weight based on the total amount of the other components.
• the First Process of the present invention for preparing the First Polymer has several advantages compared to known methods of preparing prior art phosphorus-containing reactive polyester oligomers. These advantages may include one or more of the following:
• Another aspect of the invention provides as the First Polymer of the invention a phosphorus-containing reactive polyester oligomer obtained and/or obtainable from the First Process of the invention as described herein.
• the First Polymers are preferably reactive (i.e. (alkyl)acrylatable; oxiranatable and/or isocyanatable) in a Second Process to form as a Second Polymer of the invention a phosphorus-containing unsaturated polymerisable polymer (see below).
• the First Polymer has a molecular weight (Mn measured by GPC) less than about 5,000 daltons; more preferably from about 250 to about 4,000 daltons, most preferably from about 300 to about 3,000 daltons, for example from about 300 to about 2,000 daltons.
• Mn measured by GPC molecular weight
• the First Polymer has a viscosity of from about 100 to about 70,000 mPa ⁇ s, more preferably from about 1000 to about 50,000 mPa ⁇ s, most preferably from about 10,000 to about 40,000 mPa ⁇ s.
• the viscosity values quoted herein are Hoppler viscosities measured at 60° C.
• the First Polymer has a phosphorus content of from about 0.5% to about 10.0%; more preferably from about 2.0% to about 8.0%; most preferably from about 4.0% to about 7.0% by mass of the First Polymer.
• the First Polymer has a polydispersity of at least about 1.1, more preferably from about 1.2 to about 4.0 and most preferably from about 1.5 to about 3.5.
• the First Polymer comprises a plurality of hydroxy groups it may be used as the polyol component for the preparation of phosphorous containing urethane acrylate polymers.
• This method has several advantages over known methods for preparing urethane acrylates from phosphorus-containing polyols (such as described in WO 9502004 [DSM]), and such advantages may include one or more of those described herein.
• First Polymers are used as described herein in the Second Process of the present invention to form Second Polymers of the present invention (e.g. acrylated polyester polymer precursors).
• the First Polymer comprises a P—O single bond (for example if component (iv) in the First process comprises one or more compound(s) of Formulae 2, II, IIa, IIb) then preferably the P—O bond is not incorporated into the main polymer backbone (chain) of the First Polymer so hydrolysis of the P—O bond thereon does not lead to scission of the main polymer chain of the First Polymer (and Second and Third Polymers derived therefrom). If hydrolysis and/or transesterification occurs at the P—O bond on the First Polymer (and in Second and Third Polymers derived therefrom) this is reversible where for example the P—O bond forms part of a larger ring structure.
• the First Polymer is reacted, in a step (c), with at least one acrylating agent to form a radiation-curable polymer precursor (“Second Polymer”).
• the Second Process of the invention a process for preparing a phosphorus containing polymer precursor (also referred to herein as the Second Polymer), the process comprising the step of reacting a First Polymer of the present invention as described herein, with at least one reagent (also referred to herein as the Second Reagent) comprising one or more (meth)acrylate, oxiranyl and/or isocyanate group(s).
• the Second Reagent comprises an acrylate and/or oxiranyl group. More preferred Second Reagents are selected from: (meth)acrylic acids: (meth)acrylate (alkyl)esters; oxiranyloxy containing compounds; and most preferably from: (meth)acrylic acid and/or glycidyl(meth)acrylates.
• the Second Process relates to the preparation of a phosphorus-containing polymer precursor (the Second Polymer) by direct (meth)acrylation of a phosphorus-containing reactive polyester oligomer (the First Polymer).
• An alternative preferred Second Process of the invention comprises the steps of:
• Isocyanates may be used in the Second Process as co(polymer precursors) with the First Polymer, to form as a copolymer the Second Polymer.
• Organic isocyanates which may be used to prepare polyurethane Second Polymers are preferably polyisocyanates (i.e. have two or more isocyanate groups per molecule), more preferably di- or tri-isocyanates.
• the isocyanates may be aliphatic, cycloaliphatic and/or aromatic. Examples of suitable isocyanates comprise any of those disclosed in WO 00/52016 (which is hereby incorporated by reference) and especially those described on page 17, line 14 to page 18 line 6 of this reference.
• the total quantity of organic (poly)isocyanates used to prepare Second Polymers may be from about 10% to about 60% by weight of the Second Polymer.
• the Second Process may be solvent free, preferably only reagents being used and optionally may also be free of any further purification, washing and/or isolation step(s) (work-up steps).
• a preferred aspect of the Second Process of the invention comprises a further step where the reaction product is neutralised with a weak or strong base (preferably strong base) and water is removed from the reaction mixture before the resultant product is isolated. More preferably the Second Process comprises a final work up step in which the reaction product is neutralised in situ with a strong base (such as aqueous sodium hydroxide) the water is removed by azeotropic distillation and the resultant product is collected by filtration.
• a strong base such as aqueous sodium hydroxide
• the Second Process of the present invention (or preferred features thereof) have several advantages which may include one or more of the following:
• Another aspect of the invention provides as the Second Polymer of the invention a phosphorus-containing polymer precursor obtained and/or obtainable from the Second Process of the invention as described herein.
• the Second Polymers comprise phosphorus-containing polyesters with for example (meth)acrylate, oxiranyl and/or urethane groups and these can be considered as a novel class of polymer precursors.
• Preferred Second Polymers comprise optionally substituted phosphorous containing polyester acrylates and optionally substituted phosphorous containing polyester urethane acrylates; more preferably phosphorous containing polyester alkyl(meth)acrylates.
• the Second Polymers are phosphorus-containing polymer precursors with a high phosphorus content and can be used in the applications or uses described herein for example to confer useful properties to polymers.
• the Second Polymers are particularly useful to prepare further polymers and/or compositions (such as the Third Polymers of the invention—see below) useful in at least one of the following applications: anti-corrosion, pigmentary dispersion; adhesion promotion and/or flame retardancy, especially flame retardancy.
• the Second Polymers may also have and/or impart such properties themselves.
• Compositions comprising the Second Polymer can be cured in a very convenient way [e.g. by radiation (UV, EB) or thermal curing (with thermal initiators)] to generate a cross-linked network of polymer chains in situ (the Third Polymer) which form a coating and/or film of resin (such as polyurethane acrylate or polyester acrylate) which can be flame-retardant.
• UV, EB radiation
• thermal curing with thermal initiators
• the Second Polymer has an average molecular weight (M n ) of from about 200 to about 5,000 daltons; more preferably from about 250 to about 4,000 daltons, most preferably 500 to about 3,000 daltons.
• the Second Polymer may have a M n value of from about 1,000 to about 2,000 daltons. The M n value may be measured by any suitable technique such as GPC.
• the Second Polymer has a phosphorus content of from about 0.5% to about 10.0%; more preferably from about 2.0% to about 7.0%; most preferably from about 3.0% to about 6.0% by mass of the Second Polymer.
• the Second Polymer comprises optionally substituted phosphorous containing polyesters such as those selected from: polyester acrylates; polyester oxiranyl(alkyl)acrylates [more preferably polyester glycidyl(meth)acrylates]; polyester urethane acrylates; polyurethane dispersions (optionally cross-linkable and/or crosslinked); polyesters and/or optionally cross-linked and/or cross-linkable compositions, mixtures and/or networks thereof.
• polyester acrylates polyester oxiranyl(alkyl)acrylates [more preferably polyester glycidyl(meth)acrylates]
• polyester urethane acrylates polyester urethane acrylates
• polyurethane dispersions optionally cross-linkable and/or crosslinked
• polyesters and/or optionally cross-linked and/or cross-linkable compositions, mixtures and/or networks thereof are optionally substituted phosphorous containing polyesters such as those selected from: polyester acrylates; polyester oxiranyl(alkyl)
• the Second Polymers comprises an average value for the number of repeat units per chain (denoted herein by “m”) of from about 2 to about 100, most preferably from about 2 to about 50.
• the polymers of the invention comprise a mixture of polymer chains with a substantially Gausian distribution of chain lengths. Alternatively if m is 1, this represents a monomer.
• the second polymer has a polydispersity of at least about 1.1. more preferably about 1.2 to about 4.0 and most preferably from about 1.5 to about 3.5.
• step (d) of the process at least a part of the phosphinate ester (P—O—C) bands is hydrolysed. This permits to obtain water-thinnable phosphorous compound.
• a yet other aspect of the invention provides, as the Third Process of the invention, a polymerisation method for preparing a phosphorus-containing polyester derived polymer (also referred to herein as the Third Polymer) in which the method comprises a step of initiating polymerisation in the presence of the Second Polymer of the present invention which may for example be used as a reagent, and/or co-monomer in combination with other ingredients such as (co)monomers, polymer precursors, catalysts, initiators (e.g. photo-initiators), cross-linkers and/or other additives (e.g. flame retardant additives).
• the Third Process of the invention a polymerisation method for preparing a phosphorus-containing polyester derived polymer (also referred to herein as the Third Polymer) in which the method comprises a step of initiating polymerisation in the presence of the Second Polymer of the present invention which may for example be used as a reagent, and/or co-monomer in combination with other ingredients such as (co)
• Flame retardant additives may be added during the Third Process to improve the flame retardant properties of the cured polymer (Third Polymer of the invention) with the advantage that they can be added at much lower loading to achieve a given flame retardant effect because the Third Polymer already has flame retardant properties. As such additives (if used) will be present in lower amounts, this limits their corresponding drawbacks.
• suitable flame retardant additives comprise one or more of the following and/or any compatible mixtures thereof:
• the flame retardant additives may optionally be surface treated to improve their compatibility with the polymers to which they are added.
• inorganic hydroxides may be surface treated with long chain carboxylic acid(s) and/or silane(s) as described in “Fire Retardancy of Polymeric Materials”, edited by Arthur F. Grand & Charles A. Wilkie; Marcel Dekker Inc (5000), pages 285 to 352.
• initiation of polymerisation may be achieved by any suitable means well known to those skilled in the art.
• suitable methods comprise: thermal initiation; chemical initiation by adding suitable agents; catalysis; and/or initiation using an optional initiator followed by irradiation, for example with electromagnetic radiation (photo-chemical initiation) at a suitable wavelength such as UV; and/or with other types of radiation such as electron beams, alpha particles, neutrons and/or other particles.
• electromagnetic radiation photo-chemical initiation
• UV ultraviolet
• EB electron beam
• the Third Process of the present invention (or preferred features thereof has several advantages which may include one or more of the following:
• Another still further aspect of the invention provides as the Third Polymer of the invention a phosphorus-containing polyester derived polymer obtained and/or obtainable from the Third Process of the invention.
• the Third Polymer of the invention comprises a resin which Is substantially cross-linked to form a network of linked polymer chains which may form for example a film or coating and may contain one or more pendant phosphorus moieties within the polymer chain or network.
• a yet still other aspect of the invention provides an (optionally flame retardant) coating composition comprising a Third Polymer of the present invention.
• the coating is a powder coating.
• a coating composition of the present invention may comprise a Second Polymer of the invention for example if the Third Process (polymerisation) is to occur in situ after the coating has been applied to an article.
• compositions of the invention may also comprise other ingredient(s) such as a carrier or diluent, conventionally used to formulate a composition and/or product effective (e.g. as a flame retardant) in the use for which it is designed.
• a carrier or diluent e.g. as a flame retardant
• the carrier or diluent comprises a resin
• the resin may be selected to optimise any suitable property such as hardness or durability.
• compositions of the invention can be applied, e.g. as a coating, to any type of substrate, such as, in particular, wood, artificial wood (plastics and mix wood/plastics such as MDF), textiles, fibers, metals, paper and plastics, such as polyethylene and polypropylene.
• substrates such as, in particular, wood, artificial wood (plastics and mix wood/plastics such as MDF), textiles, fibers, metals, paper and plastics, such as polyethylene and polypropylene.
• substrates such as, in particular, wood, artificial wood (plastics and mix wood/plastics such as MDF), textiles, fibers, metals, paper and plastics, such as polyethylene and polypropylene.
• useful properties such as flame retardancy
• a typical UV formulation consists of acrylated oligomers and reactive diluents which, when cured, form a highly crosslinked coating layer having properties such as chemical resistance, scratch resistance and surface hardness.
• This high crosslinked density is often associated with shrinkage of the film, limiting adhesion and flexibility on metal substrates.
• the water-thinnable phosporous-containing polymers according to this invention differ from these typical UV formulations in their behaviour on metal substrates.
• the products show excellent adhesion and flexibility on metal substrates.
• the reduced viscosity of the products resulting from their water-thinnable character allows the application of thin coating layers of between 1 to 10 microns in one pass, even at room temperature. This is highly advantageous, especially for the application of a primer coating on a metal surface.
• the water-thinnable phosporous-containing polymer according to the invention is also advantageous for applications as thick and/or exposed coating layers.
• Articles coated with a coating comprising a Third Polymer of the present invention also form part of the present invention.
• a still yet further aspect of the present invention provides a) a product; b) a component for said product; and/or c) a consumable for use with said product, which comprises at least one First Polymer, Second Polymer and/or Third Polymer of the present invention and has utility in one or more applications and/or uses described herein; preferably selected from at least one of flame retardancy, anti-corrosion, pigmentary dispersion and/or adhesion promotion; more preferably flame retardancy.
• Another aspect of the present invention provides use of at least one First Polymer, Second Polymer and/or Third Polymer of present invention in the manufacture of a) an effective product of the invention, b) component for said product(s); and/or c) a consumable for use with said product(s).
• optional substituent and/or ‘optionally substituted’ as used herein (unless followed by a list of other substituents) signifies the one or more of following groups (or substitution by these groups): carboxy, sulpho, formyl, hydroxy, amino, imino, nitrilo, mercapto, cyano, nitro, methyl, methoxy and/or combinations thereof.
• These optional groups include all chemically possible combinations in the same moiety of a plurality (preferably two) of the aforementioned groups (e.g. amino and sulphonyl if directly attached to each other represent a sulphamoyl group).
• Preferred optional substituents comprise: carboxy, sulpho, hydroxy, amino, mercapto, cyano, methyl and/or methoxy.
• organic substituent and “organic group” as used herein (also abbreviated herein to “organo”) denote any univalent or multivalent moiety (optionally attached to one or more other moieties) which comprises one or more carbon atoms and optionally one or more other heteroatoms.
• Organic groups may comprise organoheteryl groups (also known as organoelement groups) which comprise univalent groups containing carbon, which are thus organic, but which have their free valence at an atom other than carbon (for example organothio groups).
• Organo groups may alternatively or additionally comprise organyl groups which comprise any organic substituent group, regardless of functional type, having one free valence at a carbon atom.
• Organic groups may also comprise heterocyclic groups which comprise univalent groups formed by removing a hydrogen atom from any ring atom of a heterocyclic compound: (a cyclic compound having as ring members atoms of at least two different elements, in this case one being carbon).
• the non carbon atoms in an organic group may be selected from: hydrogen, halo, phosphorus, nitrogen, oxygen and/or sulphur, more preferably from hydrogen, nitrogen, oxygen and/or sulphur.
• organic groups comprise one or more of the following carbon containing moieties: alkyl, alkoxy, alkanoyl, carboxy, carbonyl, formyl and/or combinations thereof; optionally in combination with one or more of the following heteroatom containing moieties: oxy, thio, sulphinyl, sulphonyl, amino, imino, nitrilo and/or combinations thereof.
• Organic groups include all chemically possible combinations in the same moiety of a plurality (preferably two) of the aforementioned carbon containing and/or heteroatom moieties (e.g. alkoxy and carbonyl if directly attached to each other represent an alkoxycarbonyl group).
• hydrocarbo group as used herein is a sub-set of a organic group and denotes any univalent or multivalent moiety (optionally attached to one or more other moieties) which consists of one or more hydrogen atoms and one or more carbon atoms.
• Hydrocarbo groups may comprise one or more of the following groups.
• Hydrocarbyl groups comprise univalent groups formed by removing a hydrogen atom from a hydrocarbon.
• Hydrocarbylene groups comprise divalent groups formed by removing two hydrogen atoms from a hydrocarbon the free valencies of which are not engaged in a double bond.
• Hydrocarbylidene groups comprise divalent groups (represented by “R 2 C ⁇ ”) formed by removing two hydrogen atoms from the same carbon atom of a hydrocarbon, the free valencies of which are engaged in a double bond; Hydrocarbylidyne groups comprise trivalent groups (represented by “RC ⁇ ”), formed by removing three hydrogen atoms from the same carbon atom of a hydrocarbon the free valencies of which are engaged in a triple bond. Hydrocarbo groups may also comprise saturated carbon to carbon single bonds; unsaturated double and/or triple carbon to carbon bonds (e.g. alkenyl, and/or alkynyl groups respectively) and/or aromatic groups (e.g. aryl) and where indicated may be substituted with other functional groups.
• R 2 C ⁇ divalent groups
• RC ⁇ trivalent groups
• alkyl or its equivalent (e.g. ‘alk’) as used herein may be readily replaced, where appropriate and unless the context clearly indicates otherwise, by terms encompassing any other hydrocarbo group such as those described herein.
• any substituent, group or moiety mentioned herein refers to a monovalent species unless otherwise stated or the context clearly indicates otherwise (e.g. an alkylene moiety may comprise a bivalent group linked to two other moieties).
• a group which comprises a chain of three or more atoms signifies a group in which the chain wholly or in part may be linear, branched and/or form a ring (including spiro and/or fused rings).
• the total number of certain atoms is specified for certain substituents for example C 1-r organo, signifies an organic group having from 1 to ‘r’ carbon atoms.
• the substituent may replace any hydrogen atom attached to a ring atom and may be located at any available position on the ring which is chemically suitable.
• any of organic groups listed above comprise from 1 to 36 carbon atoms, more preferably from 1 to 18. It is particularly preferred that the number of carbon atoms in an organic group is from 1 to 10 inclusive.
• polyol is understood to mean a compound or polymer which comprises at least two hydroxy groups not bound to the same carbon.
• oxirane is understood to mean a species comprising at least one oxiranyl radical (also referred to herein as an oxiranyl group).
• Oxiranyl radicals comprise a 3 to 6 membered saturated heterocyclic ring which contains one oxy group with a free carbon valence on the ring and/or a direct carbon bond from the ring to another organo moiety (e.g. where the oxiranyl group comprises part of a larger molecule).
• Preferred oxiranyl radicals comprise epoxide radicals and/or oxetanyl radicals.
• An epoxide radical may be denoted by the general
• R′′ denotes H and/or an organo group, (preferably H and/or hydrocarbo) and at least one R′′ denotes a direct carbon bond to another moiety or a free carbon valence.
• R′′ denotes H and/or an organo group, (preferably H and/or hydrocarbo) and at least one R′′ denotes a direct carbon bond to another moiety or a free carbon valence.
• Compounds comprising respectively epoxide and oxetanyl radicals may be referred to respectively as epoxide(s) and oxetane(s).
• Oxiranes includes monooxtranes with one oxiranyl radical and polyoxiranes which comprise at least two oxiranyl radicals for example polyepoxides such as diepoxides and/or polyoxetanes.
• Oxiranes comprises species where the oxiranyl group is terminal or internal, preferably terminal.
• the term ‘effective’ (for example with reference to the process, uses, products, materials, compounds, monomers, oligomers, polymer precursors and/or polymers of the present invention) will be understood to denote utility in any one or more of the following uses and/or applications: anti-corrosion, pigmentary dispersion; adhesion promotion and/or flame retardancy, preferably flame retardancy.
• Such utility may be direct where the material has the required properties for the aforementioned uses and/or indirect where the material is used as a synthetic intermediate and/or diagnostic tool in preparing materials of direct utility.
• Preferred uses are those which are necessary to provide improved protection and/or resistance to flame and/or a source of heat and/or ignition.
• the term ‘optionally substituted’ does not include halo containing species.
• suitable denotes that a functional group is compatible with producing an effective product.
• the substituents on the repeating unit may be selected to improve the compatibility of the materials with the polymers and/or resins in which they may be formulated and/or incorporated to form a flame retardant material.
• the size and length of the substituents may be selected to optimise the physical entanglement or interlocation with the resin or they may or may not comprise other reactive entities capable of chemically reacting and/or cross-linking with such other resins.
• moieties, species, groups, repeat units, compounds, oligomers, polymers, materials, mixtures, compositions and/or formulations which comprise some or all of the invention as described herein may exist as one or more stereoisomers (such as enantiomers, diastereoisomers and/or geometric isomers) tautomers, conformers, salts, zwitterions, complexes (such as chelates, clathrates, interstitial compounds, ligand complexes, organometallic complexes, non-stoichiometric complexes, solvates and/or hydrates); isotopically substituted forms, polymeric configurations [such as homo or copolymers, random, graft or block polymers, linear or branched polymers (e.g.
• cross-linked and/or networked polymers polymers obtainable from di and/or tri-valent repeat units, dendrimers, polymers of different tacticity (e.g. isotactic, syndiotactic or atactic polymers)]; polymorphs (such as interstitial forms, crystalline forms and/or amorphous forms), different phases, solid solutions; combinations thereof and/or mixtures thereof.
• the present invention comprises all such forms which are effective.
• the polymers of the present invention may be prepared using one or more suitable polymer precursor(s) (including where appropriate polymers of the present invention) which may be organic and/or inorganic and comprise any suitable (co)monomer(s), (co)polymer(s) [including homopolymer(s)] and mixtures thereof which comprise suitable polymerisable functionality for example moieties which are capable of forming a bond with the or each polymer precursor(s) to provide chain extension and/or cross-linking with another of the or each polymer precursor(s) via direct bond(s) as indicated in the Formulae herein.
• the polymer precursor(s) nay be substantially un-reactive at normal temperatures and pressures.
• reagents, (and if required any optional solvents, catalysts and/or other materials) used in the processes of the invention are substantially free of halo (per se and/or as Impurities) so that the First, Second and/or Third Polymers of the invention so obtained are also substantially free of halo, without any further purification steps being required.
• the reaction mixture was stirred and heated to 110° C. under a stream of nitrogen at a flow rate of 5 litres per hour. The mixture was held at this temperature for 4 hours and then heated to 180° C. until no more water distilled (‘g’ g of water produced from the esterification reaction was collected). When the acid value reduced to less than 10 mg KOH/g, the reaction mixture was heated at 180° C. under reduced pressure vacuum for 8 hours to remove residual water. The mixture was cooled at room temperature until 31 P-NMR analysis confirmed that the addition of DOPO onto the unsaturated bonds of itaconic acid was complete (i.e.
• the diol ‘b’ corresponds to component (iii); the diacid ‘d’ corresponds to optional component (ii); the itaconic acid corresponds to component (i); and the DOPO corresponds to component (iv).
• the specific Examples 1′ to 5′ (examples of First Polymers of the invention) were prepared by the above described generic First Process with reference to Table 1 below.
• DHE denotes 1,2-dihydroxy ethane (ethylene glycol); TPG denotes tripropylene glycol; HD denotes 1,6-hexane diol; ADP denotes 1,6-hexanedioic acid (adipic acid) IPH denotes 1,3-benzene dicarboxylic acid (isophthalic acid); and ITA denotes 2-methenyl-1,4-butanedioic acid (itaconic acid.
• reaction mixture was cooled down to 50° C. and diluted with ‘g’ g of toluene.
• the reaction mixture was washed 3 times with 15% aqueous solution of sodium sulphate (10% by volume related to the organic phase) and the organic phase was recovered and heated to 85° C. in the presence of ‘h’ g of 4-methoxyphenol. Water was then removed by azeotropic distillation under reduced pressure. Once no more water separated, the organic mixture was filtered at 50° C. under pressure (6 bar).
• the p-toluenesulphonic acid (PTSA) catalyst may be removed by precipitating it from the product using suitable base “k” (which may be a weak or a strong base) in which case an aqueous washing step is avoided which increases the yield of the highly hydrophlic product.
• suitable base “k” which may be a weak or a strong base
• an aqueous washing step is avoided which increases the yield of the highly hydrophlic product.
• a base which may be a weak or a strong base
• the product was simply washed with a 20% aqueous solution of Na 2 SO 4 .
• a phosphorus containing polyester acrylate polymer precursor which determined to have the following properties: the phosphorus content of ‘1’ % w/w; Hoppler viscosity (H, 60° C.) of ‘m’ mPa ⁇ s; colour measured following the Gardner method of ‘n’ G; acid value (I AC ) of ‘o’ mg KOH/g: and a hydroxy value (I OH ) of ‘p’ mg KOH/g.
• Examples 7′ to 11′ (examples of Second Polymers of the invention) were prepared by the above described generic Second Process with reference to Tables 2 and 3 below.
• Tol denotes toluene; AA denotes acrylic acid; PTSA.H 2 O denotes p-toluenesulphonic acid monohydrate; MEHQ denotes 4-methoxyphenol (mono methylether hydroquinone); TNPP denotes trisnonylphenylphosphite; HQ denotes 1,4-dihydroxybenzene (hydroquinone); HMDA denotes 1,6-hexamethylenediamine; and NM indicates the property was not measured.
• a Second Polymer of the invention having the same structure as Example 8 herein, may solubilised as follows. To a double jacketed reactor of 0.5 litre connected to an oil bath and equipped with a stirrer were added 100 g of toluene and 200 g of the phosphorus containing reactive polyester oligomer of Example 8 (made analogously to the generic method described above and in Tables 2 & 3, the polymer having 1.63 meq DOPO/g). The reaction mixture was stirred and heated to 30° C. Then 7.6 g of sodium hydroxide in solution in 7.6 g water was slowly added to the reaction mixture. When the pH became neutral, 100 g of water was added and the reaction mixture was stirred for 10 minutes.
• the water phase containing the water-soluble polyester acrylate, was decanted. 31 P-NMR analysis of the water phase showed appearance of a new major peak (24.5–23.2 ppm) corresponding to the phosphinic sodium salt formed from hydrolysed DOPO).
• a phosphorus containing polyester urethane acrylate polymer precursor of the present invention was prepared as follows. To a one litre double jacketed reactor vessel connected to an oil bath and equipped with a stirrer, was added 404 g of the phosphorus containing diol (prepared analogously as described in Example 1′, with an acid value of 108.2 mg KOH/g), 173.2 g of isophoronediisocyanate (IPDI) and 0.76 g of 1,4-dihydroxybenzene (hydroquinone- an anti-oxidant). The reaction mixture was stirred and heated to 70° C.
• IPDI isophoronediisocyanate
• 1,4-dihydroxybenzene hydroquinone- an anti-oxidant
• B ethanol or Polymer or acetone Wt KOH methanol Wt MeHQ Wt water 25° C.
• isopropanol Ex ‘a’/g ‘b’/g ‘c’/g ‘d’/g ‘e’/g ‘f’/g ‘g’/mPa ⁇ s Wt % H T WT h 1 100 50 toluene 6.28 249 0.09 45 NM NM y y 30 2 75 3.89 — 0.07 62 NM NM y y 40 3 100 l00 ethanol 7.91 — 0.06 113 NM NM y y y 40 4 250 250 ethanol 22.0 105 0.15 45 2440 1.02 y y y 30 5 600
• Example 10 illustrates a process conducted without alcoholic solvent
• Example 11 illustrates a process conducted with catalytic amount of alcohol in the presence of a phase transfert agent
• flame retardancy as well as adhesion is confered by the primer when the primer is based on the water-thinnable polymer of the present invention.
• the present invention show that it is necessary to combine at least a primer, a sealer or several sealers and a topcoat to combine the 4 properties with excellent results: flame retardancy, adhesion on the substrate, abrasion resistance and schratch resistance. These requirements must be fullfilled for flooring applications like parquet applications.
• the primer confer excellent adhesion on the MDF-wood subtrate and confer the flame retardancy properties.
• the sealer and the topcoat confer the abrasion and scratch resistance.
• the sealer may also confer flame retardancy properties (see ex16).
• FR-primer 1 Composition parts 2 nd polymer 85 from ex 9 Irgacure 500 3 FR-primer 1 Total g/m2 Sealer Topcoat weight CRF System (dry) g/m2 g/m2 g/m2 KW/m2 FR-1 70 0 0 70 7.8 Uncoated MDF- 0 0 0 0 5.8 wood substrate
• the coated MDF-wood substrate with FR-primer 1 has a significantly higher CRF than the uncoated MDF-wood substrate and thus it has a significantly lower flamability than uncoated MDF-wood substrate.
• Example 13 Shows the Flame Retardancy of a multilayer system based on a FR-primer, a sealer and a topcoat compared to an uncoated MDF-wood substrate:
• the system 1 is defined as the MDF-wood substrate coated with 3 layers.
• compositions of the different layers are described in the following tabel:
• FR-primer 2 Sealer 1 Topcoat 1 composition parts Comp. Parts Comp. parts 2ndpolymer 100 Eb 4450 100 DPGDA 42 from ex 9 Irgacure 500 5 DPGDA 10 Eb 265 30 Sibelco M 10 Irgacure 5 Eb 810 10 6000 500 BYK 011 1 BZO 3 Darocure 2 1173 Sylo ⁇ d 161 8 Lancowax 2 PP 1362 PA 11 1 Total FR-primer 2 Sealer 1 Topcoat 1 weight CRF System g/m2 g/m2 g/m2 g/m2 KW/m2 FR-2 100 54 8 162 10.6 Uncoated 0 0 0 0 6.0 MDF-wood substrate Conclusions:
• the uncoated MDF-wood substrate has a significantly lower CRF and thus has a significantly higher flamability.
• Example showing the FR performances of a system based on an FR-primer, a sealer and a topcoat in comparaison with FR performances of a system based on a FR-primer only.
• FR-primer 1 Sealer 1 Topcoat 1 Comp. parts Comp. parts Comp. parts 2ndpolymer 85 Eb 4450 100 DPGDA 42 from ex 9 Irgacure 500 3 DPGDA 10 Eb 265 30 Irgacure 5 Eb 810 10 500 BZO 3 Darocure 2 1173 Sylo ⁇ d 161 8 Lancowax 2 PP 1362 PA 11 1 FR- primer 1 Sealer 1 Topcoat 1 Total weight CRF System g/m2 g/m2 g/m2 g/m2 KW/m2 FR-3 70 54 8 162 7.8 FR-1 70 0 0 0 8.0
• FR-primer Non FR- 1 primer Sealer 1 Topcoat 1 Comp. parts Comp. parts Comp. parts Comp. parts Comp. parts Comp. parts 2ndpolymer 85 Eb 2100 80 Eb 4450 100 DPGDA 42 from ex 9 Irgacure 3 Eb 12 20 DPGDA 10 Eb 265 30 500 Irgacure 1.5 Irgacure 5 Eb 810 10 500 500 BZO 3 Darocure 1173 2 Sylo ⁇ d 161 8 Lancowax PP 2 1362 PA 11 1 Non FR FR- primer Total Primer 1 g/m2 Sealer Topcoat weight CRF System g/m2 dry dry g/m2 g/m2 g/m2 KW/m2 FR-2 100 0 54 8 162 10.6 non FR-1 0 16 54 8 78 6.3
• Example with a FR-primer, two different sealers (FR and non FR) and a topcoat Example with a FR-primer, two different sealers (FR and non FR) and a topcoat.
• This example shows that it is possible to use the FR primer in very thin layer in combination with a FR-sealer (made according to the Patent Application WO/EP02/2390).
• the FR-sealer 1 is an 100% solid system based. Advantage of this system is that nearly no water has to be evaporated because the FR-primer is used in very thin layer.
• FR-primer 1 FR-Sealer 1 Sealer 2 Topcoat 1 Comp. parts Comp. parts Comp. parts Comp. parts Comp. parts Comp. parts 2ndpolymer 85 2d polymer 80 Eb 4450 100 DPGDA 42 from ex 9 from ex 5′ Irgacure 3 Eb 7100 5 DPGDA 10 Eb 265 30 500 DPGDA 10 Irgacure 3.5 Eb 810 10 500 talcum 5 BZO 3 Cristoballite 5 Darocure 1173 2 M 6000 Irg 500 3 Sylo ⁇ d 161 8 Lancowax PP 2 1362 PA11 1 FR- Primer 1 Sealer Topcoat Total dry FR-Sealer 1 2 1 weight CRF System g/m2 g/m2 g/m2 g/m2 g/m2 KW/m2 FR-4 11 84 54 8 157 9.65
• the solvent based FR system is a clear polyurethane solvent based (50% solid) fire retardant system. It was applied on the MDF-wood susbtrate by roller coater following the instructions of the manufacturer (product sold under the tradename Sayerlack® from Hickson coatings).
• the water-thinnable polymer (FR-1) can be used as primer because of its excellent adhesion on the MDF-wood substrate.
• a UV curable formulation was prepared by combining 90 parts of water-thinnable phosphorous polyester acrylate (as the second polymer from example 9), 5 parts of a photoinitiator (IrgacureTM 500 from Ciba), 5 parts of an amino-acrylate (EbecrylTM 7100 from Surface Specialties UCB).
• the UV formulation was applied on HDG (hot dip galvanized steel), EZ (electrozinc steel), CRS (cold rolled steel), HRS (hot rolled steel) and copper panels by means of a 5–10 ⁇ n bar coater and exposed to UV radiation from a 80 W/cm non focalised medium pressure mercury vapor lamp to obtain a tack free film.
• Cross-hatch adhesion ISO 2409
• flexibility T-bend test EN 13523-7
• impact resistance ISO/DIS 6272
• resistance to deformation ISO 1520

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• 2003
  • 2003-06-30 AU AU2003246640A patent/AU2003246640A1/en not_active Abandoned
  • 2003-06-30 ES ES03761556T patent/ES2358898T3/es not_active Expired - Lifetime
  • 2003-06-30 EP EP03761556A patent/EP1519975B1/en not_active Expired - Lifetime
  • 2003-06-30 EP EP10180126.4A patent/EP2281849B1/en not_active Expired - Lifetime
  • 2003-06-30 US US10/518,045 patent/US7132502B2/en not_active Expired - Fee Related
  • 2003-06-30 CA CA002491426A patent/CA2491426A1/en not_active Abandoned
  • 2003-06-30 WO PCT/EP2003/006907 patent/WO2004003054A1/en active Application Filing
  • 2003-06-30 AT AT03761556T patent/ATE493456T1/de not_active IP Right Cessation
  • 2003-06-30 JP JP2004516749A patent/JP2005531660A/ja active Pending
  • 2003-06-30 MX MXPA04012833A patent/MXPA04012833A/es not_active Application Discontinuation
  • 2003-06-30 DK DK03761556.4T patent/DK1519975T3/da active
  • 2003-06-30 DE DE60335545T patent/DE60335545D1/de not_active Expired - Lifetime
  • 2003-06-30 KR KR1020047021705A patent/KR20050073538A/ko not_active Application Discontinuation
  • 2003-06-30 CN CNB038179288A patent/CN1285637C/zh not_active Expired - Fee Related
  • 2003-07-01 TW TW092117937A patent/TW200413459A/zh unknown

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